Blended polypropylene composition

Abstract

A process for making a blended composition includes: i) obtaining (A) a recycled polypropylene composition from a waste plastic material, ii) melt-mixing (A) with (B) a heterophasic propylene copolymer and (C) an inorganic filler, wherein (B) consists of (al) a propylene-based matrix consisting of a propylene homopolymer/copolymer consisting of at least 90 wt % of propylene monomer units and at most 10 wt % of ethylene and/or α-olefin monomer units, and (a2) a dispersed ethylene-α-olefin copolymer, copolymer (B) has a xylene soluble content of 12 to 27 wt %, an MRI at 230° C./2.16 kg of 5.6 to 65 dg/min, wherein the recycled composition includes at least 90 wt % a propylene-based polymer, has an ash content of less than 10 wt %, an MFI at 230° C./2.16 kg of 15 to 100 dg/min, an Izod impact strength (23° C.) of 2.0 to 5.0 kJ/m2, and a flexural modulus (23° C.) of 1500 to 2000 MPa.

1 . A process for making a blended composition, comprising the steps of:
 i) processing a waste plastic material derived from post-consumer and/or post-industrial waste to obtain (A) a recycled composition,   ii) melt-mixing the recycled polypropylene composition with (B) a heterophasic propylene copolymer and (C) an inorganic filler,   wherein the heterophasic propylene copolymer consists of (a1) a propylene-based matrix,   wherein the propylene-based matrix consists of a propylene homopolymer and/or a propylene copolymer consisting of at least 90 wt % of propylene monomer units and at most 10 wt % of ethylene and/or α-olefin monomer units, based on the total weight of the propylene-based matrix and (a2) a dispersed ethylene-α-olefin copolymer, wherein the sum of the total amount of propylene-based matrix and total amount of the dispersed ethylene-α-olefin copolymer in the heterophasic propylene copolymer is 100 wt %,   the heterophasic propylene copolymer has a xylene soluble part as determined by ISO16152:2005 in an amount of 12 to 27 wt % and   the heterophasic propylene copolymer has a melt flow index as determined by ISO1133-1:2011 at 230° C. with 2.16 kg load of 5.6 to 65 dg/min,   wherein the recycled composition comprises a propylene-based polymer at an amount of at least 90 wt % with respect to the recycled composition,   the recycled composition has an ash content as determined by ISO 3451 of less than 10 wt % with respect to the recycled composition,   the recycled composition has a melt flow index as determined by ISO1133-1:2011 at 230° C. with 2.16 kg load of 15 to 100 dg/min,   the recycled composition has an Izod impact strength as determined by ISO180/1A (parallel) at 23° C. of 2.0 to 5.0 kJ/m2 and the recycled composition has a flexural modulus as determined by ISO178 (parallel) at 23° C. of 1500 to 2000 MPa.   
     
     
         2 . The process according to  claim 1 , wherein
 the amount of the recycled composition with respect to the blended composition is 10 to 90 wt %,   the amount of the heterophasic propylene copolymer with respect to the blended composition is 10 to 90 wt %, and   the amount of the inorganic filler with respect to the blended composition is 1.0 to 30 wt %.   
     
     
         3 . The process according to  claim 1 , wherein the recycled composition with respect to the blended composition is 30 to 70 wt %. 
     
     
         4 . The process according to  claim 1 , wherein the recycled composition has a melt flow index as determined by ISO1133-1:2011 at 230° C. with 2.16 kg load of 20 to 100 dg/min. 
     
     
         5 . The process according to  claim 1 , wherein the ratio of the melt flow index as determined by ISO1133-1:2011 at 230° C. with 2.16 kg load of the recycled composition to the melt flow index as determined by ISO1133-1:2011 at 230° C. with 2.16 kg load of the propylene-based matrix of the heterophasic propylene polymer is 0.1 to 5.0. 
     
     
         6 . The process according to  claim 1 , wherein the xylene soluble part of the heterophasic propylene copolymer has an intrinsic viscosity as determined by ISO1628-1:2009 in decalin at 135° C. of 2.9 to 4.6 dl/g. 
     
     
         7 . The process according to  claim 1 , wherein the propylene-based matrix of the heterophasic propylene polymer has a melt flow index as determined by ISO1133-1:2011 at 230° C. with 2.16 kg load of 20 to 150 dg/min. 
     
     
         8 . The process according to  claim 1 , wherein the propylene-based matrix is present in an amount of 65 to 81 wt %, based on the total heterophasic propylene copolymer and the amount of ethylene monomer units in the ethylene-α-olefin copolymer in the heterophasic propylene copolymer is 55 to 68 wt %. 
     
     
         9 . A process for preparing an article, comprising the process according to  claim 1  and the step of injection molding the blended composition to obtain the article. 
     
     
         10 . The process according to  claim 9 , wherein the article is an automotive part. 
     
     
         11 . The blended composition obtained by the process according to  claim 1 . 
     
     
         12 . An article comprising the blended composition according to  claim 11 . 
     
     
         13 . The article according to  claim 12 , wherein the article is an automotive part. 
     
     
         14 . A composition comprising (A) a recycled composition obtained by processing a waste plastic material derived from post-consumer and/or post-industrial waste, (B) a heterophasic propylene copolymer and (C) an inorganic filler,
 wherein the heterophasic propylene copolymer consists of (a1) a propylene-based matrix, wherein the propylene-based matrix consists of a propylene homopolymer and/or a propylene copolymer consisting of at least 90 wt % of propylene monomer units and at most 10 wt % of ethylene and/or α-olefin monomer units, based on the total weight of the propylene-based matrix and (a2) a dispersed ethylene-α-olefin copolymer, wherein the sum of the total amount of propylene-based matrix and total amount of the dispersed ethylene-α-olefin copolymer in the heterophasic propylene copolymer is 100 wt %,   the heterophasic propylene copolymer has a xylene soluble part with respect to the heterophasic propylene copolymer as determined by ISO16152:2005 of 12 to 27 wt % and   the heterophasic propylene copolymer has a melt flow index as determined by ISO1133-1:2011 at 230° C. with 2.16 kg load of 5.6 to 65 dg/min,   wherein the recycled composition comprises a propylene-based polymer at an amount of at least 90 wt % with respect to the recycled composition,   the recycled composition has an ash content of less than 10 wt % with respect to the recycled composition,   the recycled composition has a melt flow index as determined by ISO1133-1:2011 at 230° C. with 2.16 kg load of 15 to 100 dg/min,   the recycled composition has an Izod impact strength as determined by ISO180/1A (parallel) at 23° C. of 2.0 to 5.0 kJ/m2 and the recycled composition has a flexural modulus as determined by ISO178 (parallel) at 23° C. of 1500 to 2000 MPa.   
     
     
         15 . (canceled)